Method of Manufacturing a Color Changeable Fiber

ABSTRACT

A method of forming color change fiber, comprises preparing polymer base material and preparing a plurality of warp yarns and a plurality of weft yarns , wherein the plurality of warp yarns are made by mixing a polymer base material with a color changeable material with a weight percentage ratio and the plurality of weft yarns are made of a polymer base material or natural fiber; forming a polymer fiber by spinning, weaving process for the warp yarns and the weft yarns, wherein the polymer fiber is color changeable when sunlight irradiates on the polymer fiber.

TECHNICAL FIELD

The present invention generally relates to a color changeable fiber and the method of manufacturing thereof.

BACKGROUND OF RELATED ARTS

Weaving is accomplished by passing a crosswise thread in a predetermined perpendicular pattern under and over lengthwise threads. Looms increase the efficiency of weaving by providing a loom frame that supports a plurality of lengthwise threads (called warp threads). The warp threads are threaded through loops (called heddles) made of wire or string, which may be attached between top and bottom rods or bar members of a harness. When the harness is raised or lowered, it accordingly raises or lowers the attached heddles the same distance, which pull the warp threads threaded through the heddles apart from the other warp threads, creating a sometimes triangular-cross-sectioned space (called a shed) through which to pass the crosswise thread (called the weft). This eliminates the need to move the weft up and over and down and under warp threads. Instead, the weft thread is wound on a shuttle, and the shuttle is passed from one hand to the other through the shed created by the separated warp threads.

While the word thread is used throughout for convenience, it should be understood that “thread” may encompass any material that can be woven. For instance, natural fibers, synthetic fibers, filaments, yarns, reeds, paper, leather, and ribbons have all been woven. Typically for a material to be woven, a material must have a length much greater than its width.

The current anti-UV cloth uses a material to coat on a cloth. The process requires an additional coating process and the coated material is likely to be removed from the cloth, thereby causing the anti-UV function failure.

SUMMARY

The present invention provides a method of forming color change lens, comprising preparing molding base material and preparing color changeable material; mixing said molding base material and said color changeable material with a weight percentage ratio; loading said mixed molding base material and said color changeable material into a molding apparatus; forming lens by molding process by said molding apparatus with a temperature, wherein said lens is color changeable when sunlight irradiates on said lens.

If the color changeable material includes photochromic or thermal-chromic dye, the molding process includes injection molding, extrusion molding and the molding temperature is below dissociation temperature of said photochromic or thermal-chromic dye, a molding temperature is about 180-200, 200-220, 220-230, 230-250° C., and said molding base material is PC or PMMA.

If the color changeable material includes silver halide and copper oxide, the silver halide includes silver bromide, silver chloride or the combination. The molding process includes injection molding or extrusion molding. The molding temperature is about 180-200, 200-220, 220-230, 230-250, 250-280, 280-300° C. The molding base material is PC or PMMA. If the color changeable material includes titanium dioxide doped with silver, the molding process includes injection molding or extrusion molding. The molding temperature is about 180-200, 200-220, 220-230, 230-250, 250-280, 280-300° C.

A method of forming color change fiber, comprises preparing polymer base material and preparing color changeable material; mixing said polymer base material and said color changeable material with a weight percentage ratio; loading said mixed said polymer base material and said color changeable material into a melting apparatus; forming polymer fiber by spinning, weaving process, wherein said polymer fiber is color changeable when sunlight irradiates on said polymer fiber. The color changeable material includes photochromic or thermal-chromic dye wherein a melting temperature is below dissociation temperature of said photochromic or thermal-chromic dye. The melting temperature is about 180-200, 200-220, 220-230, 230-250, 250-300° C.

The color changeable material includes silver halide and copper oxide, wherein said silver halide includes silver bromide, silver chloride or the combination. The melting temperature is about 180-200, 200-220, 220-230, 230-250, 250-280, 280-300° C. The color changeable material includes titanium dioxide doped with silver, wherein a molding temperature is about 180-200, 200-220, 220-230, 230-250, 250-280, 280-300° C.

Alternatively, the present invention discloses a method of forming a color changeable fiber, comprising preparing a plurality of warp yarns and a plurality of weft yarns, wherein the plurality of warp yarns are made by mixing a polymer base material with a color changeable material with a weight percentage ratio and the plurality of weft yarns are made of a second polymer base material or natural fiber; and forming a polymer fiber by spinning, weaving process for the warp yarns and the weft yarns, wherein the polymer fiber is color changeable when sunlight irradiates on the polymer fiber.

The method further comprises a step of performing a drawnwork process before the spinning, weaving processes. The color changeable material is selected from the group consisting of silver halide, titanium dioxide doped with silver, photochromic dye and the combination thereof.

Alternatively, the plurality of weft yarns are made by mixing a first polymer base material with a first color changeable material with a first weight percentage ratio and the plurality of warp yarns are made by mixing a second polymer base material with a second color changeable material with a second weight percentage ratio. Thus, the polymer fiber changes color mixed by the first color generated by the first color changeable material and the second color generated by the second color changeable material when sunlight irradiates on the polymer fiber. The mixed color is different from the first and the second color.

Further, the plurality of weft yarns are made by mixing a first polymer base material with a color changeable material with a weight percentage ratio, and the plurality of warp yarns are made of a second polymer base material or natural fiber. Thus, the polymer fiber is color changeable when sunlight irradiates on the polymer fiber.

BRIEF DESCRIPTION OF THE DRAWING

For a better understanding of the present invention and to show how it may be implemented, reference will now be made to the following drawings:

FIG. 1 shows the diagram of the present invention.

FIG. 2 shows the diagram of the present invention.

FIG. 3 shows a process flow of forming a color changeable fiber of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Some sample embodiments of the invention will now be described in greater detail. Nevertheless, it should be recognized that the present invention can be practiced in a wide range of other embodiments besides those explicitly described, and the scope of the present invention is expressly not limited expect as specified in the accompanying claims. The following embodiment is just to illustrate rather than limiting the present invention.

FIG. 1 shows the process of the present invention, the first step 100 is to prepare the fiber material and photochromic (or thermal-chromic) dye. The fiber is plastic fiber.

The photochromic (or thermal-chromic) dye is sensitive to the ultra-ray, when the photochromic dye is irradiated by the sunlight, the material will change it color due to the chemical structure is change. Therefore, the present invention will add the photochromic or thermal-chromic dye during the melting process to melt the polymer which is used to form the polymer fiber, and optionally, the stabilizers, UV absorbers or antioxidants may be added during the melting process. The photochromic dye may be spiropyrans spiroxazines fulgide fulgimides benzopyran naphthopyran spirobenzopyran Spironaphthopyran spirobenzoxazine or spironaphthoxazine.

The weight percentage of the photochromic dye is about 0.01%-0.3%. The process temperature during the melting is preferably under 260° C. to prevent the chemical structure of the photochromic dye from being dissociation. If the system uses the PMMA as the base material, the temperature of the injection is below 230° C., preferably, 180-200° C. If PC is the base material, the temperature of the injection is below 250° C., preferably, 220-245° C. Other material could be used, such as PET, Polyamide Fiber, Nylon 6, Nylon 6.6, Nylon1, Polyester Fiber, PBT, PTT, Polyacrylonitrile Fiber, Acrylic Fiber, Polyethylene Fiber, Polypropylene Fiber (PP), Polyvinylalcohol Fiber (PVA), Polyvinylchloride Fiber (PVC), Polytetrafluoroethylene Fiber (PTFE), Polyurethane Fiber, (PU), HMPE, PPS.

Please refer to FIG. 1, the polymer fiber material (base material) is mixed with the photochromic dye, and the temperature is raised for melting the polymer fiber material, and the photochromic dye is distributed evenly within the melted polymer, step 110. The next step is drawnwork procedure to form the yarn with the dye thereof, step 120. The next step is to perform the spinning, weaving process to allow the yarn to be the fiber, step 130. The fiber may be used to manufacture cloths, hat, sock, glove, pan, skirt, umbrella, which includes the photochromic dye to absorb the UV radiation and change the color to allow the user “see” the anti-UV effect. The temperature of the melting may be 180-200, 200-220, 220-230, 230-250° C., 250-300° C. depending on the chosen polymer and the dyne. The base material should be dried with 1-5 hours depending on the quantity. Then, the dried based material is mixed with the photochromic dye by certain ratio. The ratio and the process temperature will affect the result of the color change. Further, the uppermost of the melting process temperature should be lower than the dissociation temperature of the dye. Further, the silver halide may be used alone or mixed with the photochromic dye to achieve the color change effect, in the embodiment, copper oxide maybe added during the process temperature is 220-250, 250-280° C. In another embodiment, titanium dioxide with silver may be used with the PMMA or PC to form the color change lens by the above injection or extrusion molding. The weight percentage is almost the same with the dye. The size of the particles may be 200-1000 nanometers. Nano-sized Ag deposits were formed on two commercial TiO₂ nanopowders. Under the sunlight the titanium dioxide with doped silver may change color due to the silver may catch or loss the electrons. The titanium dioxide with doped silver may be used to eliminate the bacteria on the lens, simultaneously. Preferably, the titanium dioxide may be formed on the lens surface by immersion on the solution of titanium dioxide with doped silver. Nano-sized Ag deposits were formed on two commercial TiO₂ nanopowders using a photochemical reduction method. The inactivation kinetics of nAg/TiO₂ was compared to the base TiO₂ material and silver ions leached from the catalyst. The increased production of hydroxyl free radicals is responsible for the enhanced viral inactivation. The doped silver TiO₂ material may have the color change effect as well.

The method can be introduced into the manufacture of contact lens, please refer to FIG. 2. Please refer to FIG. 2, the polymer material (base material) is mixed with the photochromic dye 200, and the temperature is raised to melting the polymer material, and the photochromic dye is distributed evenly within the melted polymer, in step 210. The next step is to perform the molding procedure to form the plastic contact lens by well-known procedure, in step 220. The next step is to perform the stripping procedure to remove the molding devices to allow the lens been the dyne contained therein, in step 230. The contact lens includes the photochromic dye to absorb the UV radiation and change the color to allow the user “see” the anti-UV and fashion effect. The temperature of the melting may be 180-200, 200-220, 220-230, 230-250° C., 250-300° C. depending on the chosen polymer and the dyne. The base material should be dried with 1-5 hours depending on the quantity. Then, the dried based material is mixed with the photochromic dye by certain ratio. The ratio and the process temperature will affect the result of the color change. Further, the uppermost of the molding process temperature should be lower than the dissociation temperature of the dye. Further, the silver halide may be used alone or mixed with the photochromic dye to achieve the color change effect, in the embodiment, copper oxide maybe added during the process temperature is 220-250, 250-280° C. In another embodiment, titanium dioxide with silver may be used with the PMMA or PC to form the color change lens by the above injection or extrusion molding. The weight percentage is almost the same with the dye. The size of the particles may be 200-1000 nanometers. Nano-sized Ag deposits were formed on two commercial TiO₂ nanopowders. Under the sunlight the titanium dioxide with doped silver may change color due to the silver may catch or loss the electrons. The titanium dioxide with doped silver may be used to eliminate the bacteria on the lens, simultaneously. Preferably, the titanium dioxide may be formed on the lens surface by immersion on the solution of titanium dioxide with doped silver. Nano-sized Ag deposits were formed on two commercial TiO₂ nanopowders using a photochemical reduction method. The inactivation kinetics of nAg/TiO₂ was compared to the base TiO₂ material and silver ions leached from the catalyst. The increased production of hydroxyl free radicals is responsible for the enhanced viral inactivation.

The IR causes the cornea, lens and vitreous humor damage, for example 0.8-1.2 micron-meter IR ray and 760-1400 nm IR ray is not good the eyes. The method can be introduced into the manufacture of contact lens with IR cut function if the anti-IR material is introduced into above embodiments alone or combination. The polymer material (base material) is mixed with the anti-IR material with size of about 80-350 nano-meter. The other procedure is similar with the above embodiments.

FIG. 3 shows the process of forming a color changeable fiber woven textile of the present invention. The color changeable fiber may be a woven textile. The first step 300 is to provide a plurality of warp yarns and a plurality of weft yarns. The warp yarns are made by mixing a first polymer base material with a color changeable material with a weight percentage ratio. For example, the wrap yarns are generated by the step 110 which fiber material and photochromic (or thermal-chromic) dye are mixed. Therefore, each of the wrap yarns includes the photochromic dye to absorb the UV radiation and change the color to allow the user “see” the color changeable effect. The weft yarns are made of fiber material (polymer base material or natural fiber), without color changeable material (photochromic dye). The following steps are to perform the spinning, weaving process to allow the warp yarns and weft yarns to be the woven textile. In the step 310, it is displacing a first group of the warp yarns in a first direction relative to a second group of the warp yarns, to create a first shed between the first and second groups of the warp yarns. The first direction is a first vertical direction. Then, the step 320 is passing a weft insertion shuttle through the first shed, in a first weft shuttle direction, to form a weft yarn. Following, the step 330 is displacing a third group of the warp yarns in a second direction relative to a fourth group of the warp yarns, to create a second shed between the third and fourth groups of the warp yarns. The second direction is a second vertical direction. The step 340 is passing the weft insertion shuttle through the second shed in a second weft shuttle direction, opposed to the first weft shuttle direction, to form an additional weft yarn. Then, the steps 310-340 are repeated for a predetermined number of times to obtain a predetermined number of the weft yarns. As mentioned above, the wrap yarns are embedded with photochromic (or thermal-chromic) dye and the weft yarns are without photochromic (or thermal-chromic) dye, and therefore the color changeable fiber (woven textile) manufactured by the wrap yarns and the weft yarns has the effects of color changeable by UV radiation and color mixing.

In another embodiment, the weft yarns are made by mixing a first polymer base material with a first color changeable material with a first weight percentage ratio and the plurality of warp yarns are made of a second polymer base material with a second color changeable material with a second weight percentage ratio. Therefore, each of the wrap yarns and weft yarns includes the color changeable material (photochromic dye) to absorb light (such as UV) irradiation and change the color to allow the user “see” the color changeable effect. For example, color of the weft yarns is changed to a first color and color of the warp yarns is changed to a second color when they absorb the light (such as UV) irradiation. Thus, the polymer fiber changes color mixed by the first color generated by the first color changeable material and the second color generated by the second color changeable material when sunlight irradiates on the polymer fiber. The first color and the second color are different, and therefore the color changeable fiber (woven textile) manufactured by the wrap yarns and the weft yarns has the effects of color changeable by light (such as UV) irradiation and color mixing. The mixed color is different from the first and the second color.

In yet another embodiment, the plurality of weft yarns are made by mixing a first polymer base material with a color changeable material with a weight percentage ratio, and the plurality of warp yarns are made of a second polymer base material or natural fiber. For example, the weft yarns are generated by the step 110 which fiber material and photochromic (or thermal-chromic) dye are mixed. Therefore, each of the weft yarns includes the photochromic dye to absorb the light irradiation and change the color to allow the user “see” the color changeable effect. The wrap yarns are made of fiber material (polymer base material or natural fiber), without color changeable material (photochromic dye).

To reduce the cost of manufacturing and increase the comfort of wearing, the wrap yarns or the weft yarns are made of polymer base material or natural fiber, without color changeable material. By mixing the polymer base material, the cost of manufacturing for the color changeable fiber may be reduced. By mixing the natural fiber, the comfort of wearing and ventilation of the color changeable fiber may be increased.

As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrated of the present invention rather than limiting of the present invention. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structure. While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. 

I claim:
 1. A method of forming a color changeable fiber, comprising preparing warp yarns and weft yarns, wherein said warp yarns are made by mixing a first polymer base material with a color changeable material with a weight percentage ratio and said weft yarns are made of a second polymer base material or natural fiber; and forming a polymer fiber by spinning, weaving process for said warp yarns and said weft yarns, wherein said polymer fiber is color changeable when sunlight irradiates on said polymer fiber.
 2. The method according to claim 1, further comprising performing a drawnwork process before said spinning, weaving processes.
 3. The method according to claim 1, wherein said color changeable material is selected from the group consisting of silver halide, titanium dioxide doped with silver, photochromic dye and the combination thereof.
 4. The method according to claim 1, wherein said first polymer base material includes Nylon, Polyester, Acrylic or Polypropylene, and said second polymer base material includes Nylon, Polyester, Acrylic or Polypropylene.
 5. The method according to claim 1, wherein said spinning, weaving process comprises: (a)displacing a first group of said warp yarns in a first direction relative to a second group of said warp yarns, to create a first shed between said first and said second groups of said warp yarns; (b)passing a weft insertion shuttle through said first shed, in a first weft shuttle direction, to form a weft yarn; (c)displacing a third group of said warp yarns in a second direction relative to a fourth group of said warp yarns, to create a second shed between said third and said fourth groups of said warp yarns; and (d)passing said weft insertion shuttle through said second shed in a second weft shuttle direction, opposed to said first weft shuttle direction, to form a second weft yarn.
 6. The method according to claim 5, further comprising repeating said step (a) to step (d) for a predetermined number of times to obtain a predetermined number of said weft yarns.
 7. A method of forming a color changeable fiber, comprising preparing warp yarns and weft yarns, wherein said weft yarns are made by mixing a first polymer base material with a first color changeable material with a first weight percentage ratio and said warp yarns are made by mixing a second polymer base material with a second color changeable material with a second weight percentage ratio; and forming a polymer fiber by spinning, weaving process for said warp yarns and said weft yarns, wherein said polymer fiber changes color mixed by said first color changeable material and said second color changeable material when sunlight irradiates on said polymer fiber.
 8. The method according to claim 7, further comprising performing a drawnwork process before said spinning, weaving processes.
 9. The method according to claim 7, wherein said color changeable material is selected from the group consisting of silver halide, titanium dioxide doped with silver, photochromic dye and the combination thereof.
 10. The method according to claim 7, wherein said first polymer base material includes Nylon, Polyester, Acrylic or Polypropylene, and said second polymer base material includes Nylon, Polyester, Acrylic or Polypropylene.
 11. The method according to claim 7, wherein said spinning, weaving process comprises: (a)displacing a first group of said warp yarns in a first direction relative to a second group of said warp yarns, to create a first shed between said first and said second groups of said warp yarns; (b)passing a weft insertion shuttle through said first shed, in a first weft shuttle direction, to form a weft yarn; (c)displacing a third group of said warp yarns in a second direction relative to a fourth group of said warp yarns, to create a second shed between said third and said fourth groups of said warp yarns; and (d)passing said weft insertion shuttle through said second shed in a second weft shuttle direction, opposed to said first weft shuttle direction, to form a second weft yarn.
 12. The method according to claim 11, further comprising repeating said step (a) to step (d) for a predetermined number of times to obtain a predetermined number of said weft yarns.
 13. A method of forming a color changeable fiber, comprising preparing warp yarns and weft yarns, wherein said weft yarns are made by mixing a first polymer base material with a color changeable material with a weight percentage ratio, and said warp yarns are made of a second polymer base material or natural fiber; and forming a polymer fiber by spinning, weaving process for said warp yarns and said weft yarns, wherein said polymer fiber is color changeable when sunlight irradiates on said polymer fiber.
 14. The method according to claim 13, further comprising performing a drawnwork process before said spinning, weaving processes.
 15. The method according to claim 13, wherein said color changeable material is selected from the group consisting of silver halide, titanium dioxide doped with silver, photochromic dye and the combination thereof.
 16. The method according to claim 15, wherein said first polymer base material includes Nylon, Polyester, Acrylic or Polypropylene, and said second polymer base material includes Nylon, Polyester, Acrylic or Polypropylene.
 17. The method according to claim 13, wherein said spinning, weaving process comprises: (a)displacing a first group of said warp yarns in a first direction relative to a second group of said warp yarns, to create a first shed between said first and said second groups of said warp yarns; (b)passing a weft insertion shuttle through said first shed, in a first weft shuttle direction, to form a weft yarn; (c)displacing a third group of said warp yarns in a second direction relative to a fourth group of said warp yarns, to create a second shed between said third and said fourth groups of said warp yarns; and (d)passing said weft insertion shuttle through said second shed in a second weft shuttle direction, opposed to said first weft shuttle direction, to form a second weft yarn.
 18. The method according to claim 17, further comprising repeating said step (a) to step (d) for a predetermined number of times to obtain a predetermined number of said weft yarns. 